Mechanically sealed housings for physiological monitors

Abstract

An enclosure for an electronic device, such as a wearable physiological monitor, may be formed of at least two different materials, e.g., a first part formed of a first material (e.g., a metal) and a second part formed of a second material (e.g., a plastic). The second part may include an opening to receive at least a portion of the first part therein, where the first part includes an anchor projecting from a surface thereof into the opening of the second part. To ensure that the enclosure is waterproof, a third part that can be chemically bonded to the second part may secure the first part by filling a volume between the anchor of the first part and an adjacent surface of the second part around the opening. In some aspects, the chemical bond between the second part and the third part creates an environmental seal around the opening.

What is claimed is: 
     
       1. A waterproof wearable physiological monitoring device, the device comprising:
 a first part, the first part including:
 a plurality of pads, each pad of the plurality of pads formed of a first material having a first melt temperature, and 
 a plurality of plates, each affixed to a first surface of one of the plurality of pads, each of the plurality of plates including at least one anchor formed along a perimeter of one of the plurality of plates and projecting from the perimeter at a first angle such that the at least one anchor is disposed above the first surface of its respective pad; 
 
 a second part, wherein:
 the second part includes a first support structure formed substantially of a second material having a second melt temperature that is lower than the first melt temperature, and 
 the first support structure includes one or more openings for each of the plurality of pads such that a second surface of each pad that opposes the first surface is exposed along an exterior surface of the device and the first surface of each pad is contained within an interior of the device; and 
 
 a third part, wherein:
 the third part includes a second support structure formed substantially of a third material having a third melt temperature that is lower than the first melt temperature, 
 the second support structure is chemically bonded to the first support structure of the second part, and 
 the second support structure encloses at least a portion of each anchor on the plurality of plates, 
 whereby the second support structure mechanically maintains a fixed relationship between the first part that has anchors enclosed by the second support structure and the second part that is chemically bonded to the second support structure. 
 
 
     
     
       2. The device of  claim 1 , wherein the third material is the same as the second material, and wherein the third melt temperature is the same as the second melt temperature. 
     
     
       3. The device of  claim 1 , wherein the first material has an electrical conductivity of at least 1×10 6  Ω −1 ·m −1 , and wherein one or more of the second material and the third material have an electrical resistivity of at least 1×10 6  Ω·m. 
     
     
       4. The device of  claim 1 , wherein the second melt temperature and the third melt temperature are between 150° C. and 350° C., and wherein the first melt temperature is between 450° C. and 2000° C. 
     
     
       5. The device of  claim 1 , wherein the first material is a metal. 
     
     
       6. The device of  claim 1 , wherein each of the second material and the third material is one or more of a polycarbonate and a thermoplastic. 
     
     
       7. The device of  claim 1 , wherein the position of each pad is maintained without use of any of adhesive, tape, or additional substrates. 
     
     
       8. The device of  claim 1 , wherein the at least one anchor includes at least two vertices with a notch formed therebetween. 
     
     
       9. The device of  claim 1 , wherein each of the plurality of plates includes at least two anchors. 
     
     
       10. The device of  claim 1 , wherein the first support structure forms at least a portion of the exterior surface of the device. 
     
     
       11. The device of  claim 1 , wherein the first support structure defines a window between the interior of the device and an exterior of the device, the device further comprising:
 a sheet formed of an optically clear polymer, the sheet defining a lens disposed along the window; and 
 a fourth material having a melt temperature less than the first melt temperature, the fourth material chemically bonded to one or more of the first support structure and the second support structure. 
 
     
     
       12. An assembly for a wearable physiological monitor comprising:
 a first part, wherein:
 the first part is formed of a first material having a first melt temperature, 
 the first part includes a first surface, and 
 the first part includes an anchor with an anchor feature having an anchor surface extending horizontally as the anchor feature extends vertically from the first surface; 
 
 a second part, wherein:
 the second part is formed of a second material having a second melt temperature lower than the first melt temperature, 
 the second part includes an opening, and 
 the first part is positioned adjacent to the second part with the anchor feature passing through the opening; and 
 
 a third part, wherein:
 the third part is formed of a third material having a third melt temperature lower than the first melt temperature, 
 the third part is secured to the second part by a chemical bond, and 
 the third part secures the first part relative to the second part by filling a volume between the anchor surface of the first part and an adjacent surface of the second part around the opening, 
 
 wherein the assembly forms a waterproof enclosure for one or more electronic components. 
 
     
     
       13. The assembly of  claim 12 , wherein the third part encloses at least a portion of the anchor feature. 
     
     
       14. The assembly of  claim 12 , wherein the chemical bond between the second part and the third part creates an environmental seal around the opening. 
     
     
       15. The assembly of  claim 12 , wherein the second part includes a rim structurally configured to laterally retain the first part relative to the second part. 
     
     
       16. The assembly of  claim 12 , wherein the third material is the same as the second material, and wherein the third melt temperature is the same as the second melt temperature. 
     
     
       17. The assembly of  claim 12 , wherein the first material is an electrically conductive material, and wherein the second and third materials are electrically resistive materials. 
     
     
       18. The assembly of  claim 12 , wherein the first material is a metal, and wherein each of the second material and the third material is one or more of a polycarbonate and a thermoplastic. 
     
     
       19. The assembly of  claim 12 , wherein the anchor includes at least two vertices with a notch formed therebetween. 
     
     
       20. An assembly for a wearable physiological monitor comprising:
 a first part, wherein:
 the first part is formed of a first material having a first melt temperature, 
 the first part includes a first surface, and 
 the first part includes an anchor with an anchor feature having an anchor surface extending horizontally as the anchor feature extends vertically from the first surface, wherein the anchor includes at least two vertices with a notch formed therebetween; 
 
 a second part, wherein:
 the second part is formed of a second material having a second melt temperature lower than the first melt temperature, 
 the second part includes an opening, and 
 the first part is positioned adjacent to the second part with the anchor feature passing through the opening; and 
 
 a third part, wherein:
 the third part is formed of a third material having a third melt temperature lower than the first melt temperature, 
 the third part is secured to the second part by a chemical bond, and 
 the third part secures the first part relative to the second part by filling a volume between the anchor surface of the first part and an adjacent surface of the second part around the opening.